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Covpress Ltd RPS ConsultantsCoventry MCERTS Report (v9) – Executive Summary
Authorisation/Permit PPC/193 Report Version: 1Date of Issue: September 2016
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Contract Reference: FTBS 45018
Operator: Covpress Ltd
Address: Burnsall RoadCanleyCoventryCV5 6RT
Monitoring Organisation: RPS Consultants
Address: Noble House, Capital Drive, LinfordWood, MK14 6QP
Report Date: 5th September 2016
Report Approved By: Glyn Harrison
Position: Operations Manager
MCERTS Registration No.: MM 03 228
MCERTS Certification Level: 2
Technical Endorsements: TE1, TE2, TE3, TE4
Signature:
RPS Consultants has produced this report within the term of the contract with the client and taking account ofthe resources devoted to it by agreement with the client.
We disclaim any responsibility to the client and others in respect of any matters outside the scope of the above.This report is confidential to the client and we accept no responsibility of whatsoever nature to third parties towhom this report, or any part thereof, is made known. Any such party relies on the report at their own risk.
Report for Periodic Monitoring of Emissions to Atmosphere
Part 1: Executive Summary
Permit Number: PPC/193
Operator: Covpress Ltd.
Installation: Coventry
Emission Point: Burn Off Oven Exhaust
Monitoring Date: 17th August 2016
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CONTENTS
Part 1: Executive Summary
Section 1 – Monitoring Objectives……………………………………………………Page 3
Section 2 – Monitoring Results………………………………………………………. Page 4
Section 3 – Operating Information……………………………………………………Page 5
Section 4 – Monitoring Deviations……………………………………………………Page 6
Part 2: Supporting Information
Appendix 1 – Staff & Methodology Details
Appendix 2 – Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
Appendix 3 – Laboratory Data
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Section 1 – Monitoring Objectives
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Monitoring Objectives
At the request of Steve Cottom of Covpress Ltd, RPS Consultants conducted stackemission monitoring at the Coventry site in August 2016.
The monitoring programme at this installation was carried out to provide data onemissions to atmosphere for comparison with the limits specified in the air emissioncriteria for this site.
The following tables detail the parameters requested for monitoring at each emissionpoint and the actual monitoring conducted.
Table 1.1
Parameters Requested to be MonitoredEmission Point
Burn Off Oven Exhaust
Total Particulate Matter
Volatile Organic Compounds
Oxides of Nitrogen
Carbon Monoxide
Total Particulate Matter
Specific Requirements Long Cycle ‘Burn Off’(~270 minutes)
Notes: Represents pollutants sampled
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Section 2 – Monitoring Results
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Monitoring Results
Table 2.1 Monitoring results for the Burn Off Oven Exhaust, Carried out on 17th August 2016.
Substance MonitoredEmission
LimitValue
PeriodicMonitoring
ResultUnits
Uncertainty(Expressed
expanded k=2)
ReferenceConditions
SamplingDate
SamplingTimes
MonitoringReference
MethodAccreditation
StatusOperating
Status
Carbon MonoxideNo Limit 275 mg/m3 +/- 17 273K, 101.3kPa,
Dry, 11%Oxygen
17/08/16 10:04 –14:30
BS EN15058:2006 MCERTS Normal
No Limit 0.13 kg/hr -
Oxides of NitrogenNo Limit 99 mg/m3 +/- 5.8 273K, 101.3kPa,
Dry, 11%Oxygen
17/08/16 10:04 –14:30
BS EN14792:2005 MCERTS Normal
No Limit 0.048 kg/hr -
Total Particulate Matter20 52 mg/m3 +/- 2.3 273K, 101.3kPa,
Dry, 11%Oxygen
17/08/16 10:04 –14:34
BS EN13284-1:2002 MCERTS Normal
No Limit 0.024 kg/hr -
Volatile OrganicCompounds (as Carbon)
20 8.0 mg/m3 +/- 0.25 273K, 101.3kPa,Dry, 11%Oxygen
17/08/16 10:04 –14:34
BS EN12619:2013 MCERTS Normal
No Limit 0.0039 kg/hr -
Note :
Result in bold type is over the Emission Limit Value Tests were undertaken during a ‘long cycle’ burn off
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Section 3 – Operating Information
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Operating Information
Table 3.1 Operating conditions during the monitoring of the Burn Off Oven Exhaust, carried out on 17th August 2016
Parameter ResultComparison of Operator CEM and Periodic Monitoring Results
Substance CEMs Results(mg/m3)
Periodic MonitoringResults (mg/m3)
Sample Date 17/08/16 No CEMS Installed/Data Available
Process Type Batch
Process Duration 270 Minutes
If ‘Batch’, was monitoringcarried out over the whole
batch?Yes
Abatement/Operational? Not Installed
Load Oven loaded with “UK” bars.
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Section 4 – Monitoring Deviations
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Monitoring Deviations
Table 4.1 Monitoring Deviations for Burn Off Oven Exhaust Emission Point
Pollutant Substance Deviations Monitoring Deviations Other Relevant Issues
Carbon Monoxide,Oxides of Nitrogen &
Volatile OrganicCompounds
None None None
Total Particulate Matter None Monitoring conducted from a singletraverse line. None
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Contract Reference: FTBS 45018
Operator: Covpress Ltd
Address: Burnsall RoadCanleyCoventryCV5 6RT
Monitoring Organisation: RPS Consultants
Address: Noble House, Capital Drive, LinfordWood, MK14 6QP
Report Date: 5th September 2016
Report Approved By: Glyn Harrison
Position: Operations Manager
MCERTS Registration No.: MM 03 228
MCERTS Certification Level: 2
Technical Endorsements: TE1, TE2, TE3, TE4
Signature:
RPS Consultants has produced this report within the term of the contract with the client and taking account ofthe resources devoted to it by agreement with the client.
We disclaim any responsibility to the client and others in respect of any matters outside the scope of the above.This report is confidential to the client and we accept no responsibility of whatsoever nature to third parties towhom this report, or any part thereof, is made known. Any such party relies on the report at their own risk.
Report for Periodic Monitoring of Emissions to Atmosphere
Part 2: Supporting Information
Permit Number: PPC/193
Operator: Covpress Ltd.
Installation: Coventry
Emission Point: Burn Off Oven Exhaust
Monitoring Date: 17th August 2016
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CONTENTS
Part 1: Executive Summary
Section 1 – Monitoring Objectives……………………………………………………Page 3
Section 2 – Monitoring Results………………………………………………………. Page 4
Section 3 – Operating Information……………………………………………………Page 5
Section 4 – Monitoring Deviations……………………………………………………Page 6
Part 2: Supporting Information
Appendix 1 – Staff & Methodology Details
Appendix 2 – Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
Appendix 3 – Laboratory Data
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Appendix 1: General Information
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APPENDIX 1: General Information
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Appendix 1: General Information
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Monitoring Organisation Staff Details
Table 5.1 Sampling Personnel
SamplingPersonnel Role MCERTS
LevelTechnical
EndorsementsMCERTS
RegistrationNumber
Carl Redgrove Team Leader Level 2 TE1, TE2, TE3,TE4 MM 03 173
Jack Richmond Technician - - MM 15 1361
Table 5.2 Report Author
Report Author Position MCERTSLevel
TechnicalEndorsements
MCERTSRegistration
Number
Carl Redgrove Senior Consultant Level 2 TE1, TE2, TE3,TE4 MM 03 173
Table 5.3 Report Reviewer
Report Reviewer Position MCERTSLevel
TechnicalEndorsements
MCERTSRegistration
Number
Glyn Harrison OperationsManager Level 2 TE1, TE2, TE3,
TE4 MM 03 228
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Appendix 1: General Information
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Monitoring Organisation Method Details
Table 6.1 Monitoring Methods
Emission Parameter StandardMethod
MonitoringProcedure
No.Monitoring
Accreditation AnalysisAnalysis
ProcedureNo.
AnalyticalLaboratory
AnalysisAccreditation
Practical ConsiderationsPrior to Monitoring N/A RPSCE/1/1 UKAS N/A N/A N/A N/A
Gas Flows BS-EN 16911-1 RPSCE/1/2 MCERTS N/A N/A N/A N/A
Gas Temperatures BS-EN 13284-1:2001 RPSCE/1/2 MCERTS N/A N/A N/A N/A
Carbon Monoxide EN 15058:2006 RPSCE/1/21h MCERTS NDIR N/A N/A N/A
Oxides of Nitrogen EN 14792:2005 RPSCE/1/21f MCERTS Chemiluminescence N/A N/A N/A
Low Concentration TotalParticulate Matter
BS EN 13284-1:2002 RPSCE/1/7c MCERTS Gravimetric D9 RPS
Laboratories UKAS
TOCs BS EN12619:2013 RPSCE/1/4b MCERTS Flame Ionisation
Detector N/A N/A N/A
Table 7.1 – Checklist Used
Equipment Checklist Used File Location Address
FTBS 45018 Checklist FTBS 45018 Electronic & Work File
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Appendix 2: Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
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APPENDIX 2:Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
Covpress Ltd RPS ConsultantsCoventry MCERTS Report (v9) – Part 2 – Summary Information
Appendix 2: Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
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Burn Off Oven Exhaust – Stack Diagram
4”SampleHole
>5m
GuardRails
DuctDiameter0.40m
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Appendix 2: Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
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Company Name: Covpress In-stack Filter? No Bar. Press.mm H 758 K Factor 5.578583632 Ambient Temp. Leak Rate (fin / %) 0Site Name: CoventryProject Reference: FTBS45018 Outstack Filter? Yes Cp 0.847 Dn used 9.283 Start Time 10:04 Leak Rate (start / % 0Date: 17/08/16Run: TPM Operators CR JR Bws% Nozzle No. Stop Time 14:34 Box/Probe setting 160 +/- 5 oCSampling Point Ref: Burn Off Oven
Meter Correction Yd 0.996Sample Filter Weights Sample Filter Blank Weighings Impinger Weights
Sample ID Laboratory Increase, mg Sample ID Laboratory Increase, mg Weights Initial Final Increase, gFilter 135269 RPS 4.65 Filter 135266 RPS 0.23 Impinger 1 686.1 793.7 107.6Probe Washings 30010682 RPS 59.02 Probe Wash 30010681 RPS 0.5 Impinger 2 699.1 718.7 19.6
Note: Results in Bold are reported at the L.O.D. Impinger 3 581.2 578.1 -3.1Impinger 4 0.0Impinger 5 0.0Silica Gel 937 942.1 5.1
Total 129.2
Sample Point Clock Time Pitot D p, Stack Temp, Filter Box Probe Pump Impinger Root D p,min mm H2O
oC Temp Temp Vacuum Stem Temp.
Desired Actual oC oC oC Inches Hg oC
0 1 300 5.6 5.6 19 120 0 19 1.000
10 1 700 5.6 5.6 18 120 0 18 1.000
20 1 760 5.6 5.6 20 120 0 19 1.000
30 1 736 5.6 5.6 22 120 0 19 1.000
40 1 764 5.6 5.6 23 120 1 20 1.000
50 1 757 5.6 5.6 24 120 2 20 1.000
60 1 762 5.6 5.6 25 120 3 20 1.000
70 1 765 5.6 5.6 25 120 4 20 1.000
80 1 752 5.6 5.6 26 120 5 15 1.000
90 1 750 5.6 5.6 27 120 6 17 1.000
100 1 771 5.6 5.6 27 120 7 17 1.000
110 1 784 5.6 5.6 28 120 8 17 1.000
120 1 757 5.6 5.6 29 120 9 17 1.000
130 1 763 5.6 5.6 31 120 10 17 1.000
140 1 772 5.6 5.6 32 120 11 18 1.000
150 1 770 5.6 5.6 32 120 12 18 1.000
160 1 745 5.6 5.6 32 120 0 18 1.000
170 1 765 5.6 5.6 33 120 0 18 1.000
180 1 732 5.6 5.6 34 120 0 18 1.000
190 1 738 5.6 5.6 34 120 0 18 1.000
200 1 757 5.6 5.6 34 120 0 18 1.000
210 1 722 5.6 5.6 34 120 0 18 1.000
220 1 732 5.6 5.6 34 120 0 18 1.000
230 1 704 5.6 5.6 34 120 0 17 1.000
240 1 765 5.6 5.6 34 120 0 18 1.000
250 1 735 5.6 5.6 34 120 0 18 1.000260 1 517 5.6 5.6 34 120 0 18 1.000
Endpoint 270270.00 1.000 725.0 5.6 5.6 28.9 #DIV/0! 120.0 #DIV/0! 2.9 18.1 1.0
Temp at GasMeter Outlet
oC
CondenserTemp,
m3
1561530
Orifice D H, mm H2OGas Meter Reading
2.1361563666
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Appendix 2: Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
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Company Name: CovpressSite Name: Coventry Date: 17/08/16Project Reference: FTBS45018
Sampling Point Ref: Burn Off Oven Run: TPMMeter Volume Sampled, acm 2.136Sample Run Start Time 10:04Sample Run End Time 14:34Total Actual Sampling Time, min 270.0Barometric Pressure, mm Hg 758.00Stack Pressure, mm Hg 758.09Average Stack Temp, oC 725.0Meter Volume at STP, scm 1.919Stack Moisture Content, % 7.7Average Stack Velocity, m/sec 6.389Nozzle Diameter, mm 9.28% Isokinetic Variation 108.6Total Mass of Particulate, mg 63.7Percentage of Total Particulate Collected on Filter 7.3Stack Particulate Concentration, mg/m3 52.305Particulate Mass rate, kg/hour 0.0241Emission Limit value 20
0.550.73
Blank Result Less than 10% of Limit Value YTotal Weight Gain, mg (Sample Train Blank)
Sample Train Blank ResultsSample Blank Particulate Concentration, mg/m3
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Appendix 2: Burn Off Oven Exhaust Sampling, Analysis & Uncertainty Data
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Uncertainty Calculation for Total Particulate Matter to BS EN 13284-1
52.305
Measured Values
2.136 m3
301.8518519 k
101.08 kPa
0 % by volume
14.62 % by volume 0.00 %
63.67 mg 0 mg
Standard Uncertainties for Measured ValuesSampled Volume 0.001 m3
Sampled gas Temperature 2 k
Sampled gas Pressure 1 kPaSampled gas Humidity 1 % by volume
Oxygen content 0.1 % by volume0.14152385 mg
Uncertainty Calculation for Volume Correction Uncertainty Calculation for Oxygen Correction
0.902 1.5764SensitivityCoefficient
Uncertainty,Uv
SensitivityCoefficient
Uncertainty,Uo
0.0030 0.0060 0.2486 0.0249
0.0089 0.0089
0.0090 0.0090Sqrt (Uv)^2 0.0140Total Uv 0.030 Total Uo 0.0249
Uncertainty Contributions (Itemised)
1.919 m3 0.82 mg.m-3 1.56 %63.67 mg 0.12 mg.m-3 0.22 %1.5764 0.83 mg.m-3 1.58 %0.00 mg.m-3 0.00 mg.m-3 0.00 %0.00 mg 0.00 mg.m-3 0.00 %
1.17 mg.m-3
Uncertainty Result (Uncertainty has been expanded with a coveragefactor of 2 (K=2))
2.3344 mg.m-3
=> 4.46 % of Result
=> 11.67 % of ELV
Expanded Uncertainty =
Sensitivity coefficient
27.260.8233.181.000.82Total Uncertainty
System LeakUncollected Mass
Volume CorrectionMass (weighing)
Oxygen Correction
Mass
Leak
Uncollected Mass
ValueConcentration
Uncertainty Contribution%
Sampled gas Pressure
Sampled gas Humidity
Sampled gas Humidity
mg/m3 (at Reference Cond)
Oxygen Correction Factor
Oxygen Measurement
Mass
Volume Correction Factor
Determined Concentration
Oxygen content
Sampled gas Temperature
Sampled Volume
Sampled gas Temperature
Sampled gas Pressure
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Studied Concentration (mg/m3 as C) 8.036857063Range of Instrument (mg/m3 as C) 1607
Sampling Parameters to be met Requirement Met?Response Time < 60s YesOperating temperature (5 - 45oC) YesAtmospheric pressure (700 - 1240 mbar) YesRelative Humidity (10 - 90%, noncondensing) YesAltitude (< 2000 m) YesZero Drift 2% of FS YesSpan Drift 4% of FS Yes
Selected Performance Characteristic% Numerical Units
Deviation from Linearity 1 0.01 % FSRepeatability Standard Deviation 1 0.01 % FS8 Hour Drift 2 0.02 %Atmospheric Pressure Dependence 0.1 0.001 % kPaTemperature Dependence 0.2 0.002 %KSum Interference 2 0.02 %Voltage Supply 0.1 0.001 %VUncertainty of Calibration Gas 2 0.02 %Moisture Effect 1 0.01 %Vol H2O ErrorLoss in sample line (Leaks) 2 0.02 %
Performance Characteristic Uncertainty Quantity Units U U2 U U2
Deviation form Linearity UFit % FS 16.07 258.245 0.0803686 0.006Repeatability Standard Deviation UR % FS 0.046 0.002 0.046 0.0028 Hour Drift Udrif t % 0.0928 0.009 0.093 0.009Atmospheric Pressure Dependence UAtmos % / kPa 0.005 0.000 0.005 0.000Temperature Dependence UTemp % / K 0.009 0.000 0.009 0.000Sum Interference UInterf erence % 0.093 0.009 0.005 0.000Voltage Supply UVoltage % / V 0.005 0.000 0.005 0.000Uncertainty of Calibration Gas UCalibration gas % 0.093 0.009 0.093 0.009Loss in sample line (Leaks) ULosses, leak % 0.093 0.009 0.186 0.034
Sum 16.506 258.282 Sum 0.521 0.060
Measurement Uncertainty at 8.036857063 mg/m3 CUtot 0.246 mg/m3 C
Utot/c 3.059 % Ulimit 30 %
ISO 14956 Calculation Sheet - TOC (BS EN 12619)
%K0.02 2 %
0.002
10.001
Value of Performance CharacteristicVariable due to sampling conditions
0.021 % kPa
1 %V
1
0.02 1 %
% FS0.01 1 % FS0.01
%
0.001
UnitsOperating Conditions compared to calibration condition
Required1
Units% FS% FS
Measurement Performance related to stationary conditions
0.01 2 %Vol H2O Error2
% / V%%
%% / kPa% / K
%
At Calibration Conditions At Sampling ConditionsValue of Uncertainty Quantity
0.02 %
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Appendix 3: Laboratory Data
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APPENDIX 3:Laboratory Data
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Appendix 3: Laboratory Data
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